U.S. patent application number 11/150789 was filed with the patent office on 2005-10-13 for bus construction.
Invention is credited to Timmermans, Joseph.
Application Number | 20050227539 11/150789 |
Document ID | / |
Family ID | 38792737 |
Filed Date | 2005-10-13 |
United States Patent
Application |
20050227539 |
Kind Code |
A1 |
Timmermans, Joseph |
October 13, 2005 |
Bus construction
Abstract
A method for constructing a bus, wherein a module associated
with the front end of the bus is separately constructed and
assembled to the shell after interior components of the bus have
been installed. The shell of the bus can be fabricated at a first
work station. The shell can be made transversely or laterally with
respect to the longitudinal access of the bus to one or more work
stations. At the subsequent work stations, interior components of
the bus can be moved through the open ends of the bus. After the
majority of the interior components have been installed with
respect to the bus, the module supporting the windshield and bumper
can be installed with respect to the shell. The module can also
support the dashboard and steering column.
Inventors: |
Timmermans, Joseph;
(Ortonville, MI) |
Correspondence
Address: |
YOUNG & BASILE, P.C.
3001 WEST BIG BEAVER ROAD
SUITE 624
TROY
MI
48084
US
|
Family ID: |
38792737 |
Appl. No.: |
11/150789 |
Filed: |
June 10, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11150789 |
Jun 10, 2005 |
|
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10350466 |
Jan 24, 2003 |
|
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60352702 |
Jan 28, 2002 |
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Current U.S.
Class: |
439/607.41 |
Current CPC
Class: |
B62D 65/02 20130101;
Y10T 29/53365 20150115; Y10T 29/49622 20150115; Y10T 29/49826
20150115; B62D 31/02 20130101; Y10T 29/534 20150115; B62D 47/02
20130101 |
Class at
Publication: |
439/610 |
International
Class: |
H01R 009/03 |
Claims
What is claimed is:
1. In a motor vehicle assembly line for assembling a mass
transportation motor vehicle body, the mass transportation motor
vehicle body comprising: an elongate vehicle body lattice structure
for supporting separately assembled roof, floor, and side body
panels, the vehicle body lattice structure including a plurality of
seats, floor panels, and having an open longitudinal end; and a
separate unitary front-end panel having a plurality of
pre-installed members for enclosing the open longitudinal end of
the vehicle body lattice structure, the pre-installed members
including an outer fascia.
2. The motor vehicle body of claim 1, wherein the pre-installed
members further include a bumper.
3. The motor vehicle body of claim 1, wherein the pre-installed
members further include a steering column assembly.
4. The motor vehicle body of claim 1, wherein the pre-installed
members further include at least one headlamp assembly.
5. The motor vehicle body of claim 1, wherein the pre-installed
members further include an instrument panel.
6. The motor vehicle body of claim 1, wherein the pre-installed
members further include a windshield.
7. The motor vehicle body of claim 1, wherein the pre-installed
members further include at least one of a member for actuating a
braking mechanism, a member for controlling an engine throttle, and
a member for initiating shifting of a transmission.
8. A mass transportation motor vehicle body comprising: an elongate
vehicle body lattice structure for supporting separately assembled
roof, floor, and side body panels, the vehicle body lattice
structure having an open longitudinal end; and a unitary front-end
module removably connected to the lattice structure for enclosing
the open longitudinal end of the lattice structure, the unitary
front-end module being entirely detachable from the body lattice
structure as a single unit, the front-end module including a front
fascia and windshield.
9. The motor vehicle body of claim 8, wherein the front-end module
further includes a bumper.
10. The motor vehicle body of claim 8, wherein the front-end module
further includes a steering column assembly.
11. The motor vehicle body of claim 8, wherein the front-end module
further includes a headlamp assembly.
12. The motor vehicle body of claim 8, wherein the front end module
further includes an instrument panel.
13. The motor vehicle body of claim 8, wherein the front-end module
further includes at least one of a member for actuating a braking
mechanism, a member for controlling an engine throttle mechanism,
and a member for initiating shifting of a transmission.
14. A roof support structure for a mass transportation motor
vehicle body, the roof structure comprising: an elongate first side
rail having a forward end and an aft end; an elongate second side
rail having a forward end and an aft end, the second side rail
displaced away from and aligned substantially parallel to the fist
side rail; a first elongate cross-member having a first end
attached to the first side rail and a second end attached to the
second side rail; a second elongate cross-member having a first end
attached the first side rail and a second end attached to the
second side rail, wherein the first end of the first cross-member
is attached to the first side rail forward of the first end of the
second cross-member, and the second end of the second cross-member
is attached to the second side rail forward of the second end of
the second cross-member.
15. The roof support structure of claim 14, wherein the first
cross-member is attached the second cross-member.
16. The roof support structure of claim 14, wherein the first
cross-member includes a first beam and a second beam, an end of the
first beam being positioned adjacent an end of the second beam,
each of the first and second beams having an end attached to the
second cross-member.
17. The roof support structure of claim 14 further comprising a
reinforcing member attached to the first and second cross-members
and detached, the reinforcing member being detached from the first
and second side rails.
18. The roof support structure of claim 14, wherein each of the
first and second cross-members includes a first beam and a second
beam, an end of the first beam of the first cross-member being
attached to an end of the second beam of the second cross-member
and an end of the second beam of the first cross-member being
attached to an end of the first beam of the second
cross-member.
19. The roof support structure of claim 18, wherein the end of the
first beam of the first cross-member is attached to the end of the
first beam of the second cross-member.
20. The roof support structure of claim 18 further comprising a
reinforcing member attached to the first and second beams of the
first cross-member and the first and second beams of the second
cross-member.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 10/350,466 for a Bus Construction, filed Jan. 24, 2003, which
claims the benefit of U.S. Provisional Application No. 60/352,702
for a Bus Construction, filed Jan. 28, 2002, both of which are
hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to a method of manufacturing a motor
vehicle bus and to the bus structure resulting from the invention
methodology.
BACKGROUND OF THE INVENTION
[0003] Buses are typically manufactured by forming a closed shell
structure including a roof, a structural floor, sides, front-end,
and rear-end, moving the closed shell structure along a path
aligned with the longitudinal axis of the structure, and loading
components of the bus into the shell structure through the windows,
doors, or windshield opening. The components may include, for
example, the seats and the passenger compartment floor. This method
is time consuming and labor intensive since it involves loading
individual components into the bus individually and through
relatively small apertures in the shell structure.
SUMMARY OF THE INVENTION
[0004] According to the invention, the shell structure is formed
with an open front-end; the shell structure is moved laterally from
station to station in a direction generally normal to the
lengthwise axis of the shell structure; the interior components of
the bus are loaded into the interior of the shell structure through
the open front-end; a front-end module is attached to the front of
the shell structure to close the front-end of the bus shell; the
wheel assemblies are installed; and the shell structure is moved on
its wheels along its lengthwise axis to various stations where the
windows, doors, windshield, and exterior cladding are applied from
locations generally outside of the shell structure.
[0005] Other applications of the present invention will become
apparent to those skilled in the art when the following description
of the best mode contemplated for practicing the invention is read
in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The description herein makes reference to the accompanying
drawings wherein like reference numerals refer to like parts
throughout the several views, and wherein:
[0007] FIG. 1 is a perspective exploded view of a bus shell
structure according to the invention;
[0008] FIG. 2 is a perspective exploded view of an alternate shell
structure;
[0009] FIG. 3 is a layout view of an assembly plant for forming the
bus structure;
[0010] FIG. 4 is a perspective view illustrating the loading of the
seats into the shell structure; and
[0011] FIG. 5 is a perspective schematic view illustrating the
loading of the passenger floor into the shell structure.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0012] As seen in FIG. 4, the plant 10 for assembling the bus
structure includes assembly stations 1-7 and pre-assembly stations
8-17.
[0013] The basic bus shell structure 20 is formed in known manner
at station 1 utilizing known assembly techniques and known jigs.
Specifically, shell structure 20 includes lattice members 20a
forming the sides of the shell, lattice members 20b forming the
roof of the shell, and lattice members 20c forming the structural
floor of the shell. Note that the front and rear ends 20e and 20d
of the shell structure are open. The front-end of the shell
structure, rather than being formed initially at station 1 as a
fixed part of the shell structure, is formed as a separate module
structure 22 in the pre-assembly area 15. Following formation of
the shell structure 20 at station 1, minus the front module 22, the
shell structure is moved in a direction lateral to the lengthwise
axis of the shell structure, utilizing suitable dollies, to station
2 where the passenger floor of the bus is installed in overlying
relation to the structural floor 20c.
[0014] As best seen in FIG. 4, the passenger floor or over-floor 24
may be prepared in two sections 24a and 24b at pre-assembly station
8 whereafter both sections are moved from pre-assembly station 8
through the open front-end 20e of the shell structure for
installation in the shell structure. Floor structure 24a will be
understood to be installed over the usual kick-up overlying the
rear axle of the vehicle and floor section 24b will be understood
to be installed forwardly of section 24a to cover the primary floor
area of the shell structure. Floor sections 24a, 24b may be secured
to the shell structure 20 using suitable glues for example. Floor
sections 24a, 24b may be initially installed in the shell structure
in an upperwardly tilted position, as seen in dash lines FIG. 4,
whereafter they may be pivoted downwardly to their flat installed
positions.
[0015] Following the floor installation at station 2 the shell
structure 20 is moved laterally on the dollies to assembly station
3 where the engine assembly 26, prepared in pre-assembly station 9,
may be installed through open rear end 20d of the shell structure
and the seats 28, prepared at pre-assembly station 10, may be
installed through the open front-end 20e of the shell structure.
With reference to FIG. 5, the seats may be installed utilizing a
forklift 30 positioned at pre-assembly station 10 and equipped with
a boom 32 extending forwardly from the mast of the lift truck and
including a plurality of pins 34 each hangably supporting a bus
seat 28. With this arrangement the forklift may be maneuvered to
insert the boom 32 carrying the seats 28 into the interior of the
shell structure 20 through the open front-end 20e of the shell
structure to position the seats proximate their ultimate locations
in the bus, whereafter it is a simple matter to remove the seats 28
from the respective pins 34 and install the seats in the bus,
thereby minimizing the amount of movement required to install each
seat and specifically avoiding the awkward problem of moving each
seat into the interior of the bus through a narrow window or side
door opening and thereafter moving the seat lengthwise in the bus
to its proper location. The seats are installed in the bus
employing the usual bolting techniques.
[0016] Following installation of the engine assembly and the seats,
the shell structure is moved laterally on the dollies to assembly
station 4 where further interior and engine components are
installed with the engine components being prepared at pre-assembly
station 11 and installed through the open rear 20d of the shell
structure and the interior components being prepared at
pre-assembly station 12 and installed through the open front-end
20e of the shell structure.
[0017] The shell structure is thereafter moved laterally on the
dollies to assembly station 5 where further interior components may
be installed through the open front-end 20e of the shell structure
from pre-assembly station 13 and a heating and air conditioning
unit 36 (HVAC), prepared at pre-assembly station 14, may be
installed through the rear 20d of the shell structure in overlying
relation to engine assembly 26.
[0018] The shell structure is thereafter moved laterally on the
dollies to assembly station 6 where the front-end module 22, which
has been formed at pre-assembly station 15, is suitably attached to
the front-end 20d of the shell structure utilizing, for example,
bolts whereby to close the open front-end 20e of the shell
structure. Module 22 may include instrument panel 38, windshield
40, steering column assembly 42, headlamp assemblies 44, front
bumper 46, as well as suitable brake, throttle, and shift controls.
Alternatively, as seen in FIG. 2, the front module may include only
the windshield and front fascia and bumper of the bus with the
instrument panel, steering column assembly, and vehicle controls
being formed as a part of the main body shell structure 20.
Following attachment of the module 22 at station 6, the shell
structure is suitably elevated, the dollies are removed, and front
and rear axle/wheel assemblies 48, 50, prepared at pre-assembly
station 16, are slid under and suitably attached to the shell
structure so that the shell structure is now supported for rolling
movement on its wheels.
[0019] The bus is now rolled on its wheels in a direction parallel
to the lengthwise axis of the shell structure to assembly station 7
where the bus windows 52, doors 54, 56 and side cladding 58 maybe
installed from the pre-assembly station 17 wherein the installation
takes place primarily from labor performed outside the opposite
sides of the shell structure.
[0020] From station 7 the bus may be moved longitudinally on its
wheels to further stations (not shown) where further exterior
componentry may be suitably added whereafter the bus may be moved
to suitable test and inspection stations.
[0021] The described bus structure and manufacturing methodology
has several advantages as compared to prior art structures and
methodologies. To wit:
[0022] the use of a modular front-end that is not attached to the
main body shell structure until a later point in the assembly
process allows all of the major interior components of the bus to
be installed through the open front-end of the bus, rather than
through narrow openings provided by the side doors and side windows
of the shell structure where the front-end is fixedly secured to
the main body shell structure prior to the installation of the
interior components;
[0023] the late phase attachment of the front-end module allows an
L-shaped assembly process wherein the bus is moved initially
laterally through several stations in a direction normal to the
lengthwise axis of the bus whereafter, following attachment of the
front-end module and installation of the axle/wheel assemblies, the
bus is moved in a direction parallel to the lengthwise axis of the
bus. This L-shaped assembly format allows the provision of
pre-assembly areas in the area defined between the legs of the L
and in the areas along the outer faces of the legs whereby to
provide a compact factory floor package plan with a substantial
savings in floor space;
[0024] the use of the modular front-end allows the front-end to be
removed in the event of a front-end accident and replaced
immediately with a new replacement front-end so that the bus is out
of service only for the time required to install the new front-end
rather than for the much longer time required to repair the
front-end;
[0025] the use of pre-assembly areas in parallel relation to the
main assembly line to fabricate all of the primary sub-assemblies
of the vehicle minimizes the number of workers working on the bus
as it moves along the main assembly line, whereby to simplify the
assembly procedures along the main assembly line;
[0026] the use of multiple pre-assembly areas allows specialists in
each sub-assembly operation to be stationed at the respective
sub-assembly areas, whereby to assure accurate, precise
pre-assembly of the various sub-assembly components; and
[0027] the ability to install the floor through the open front-end
of the shell structure in two large sections is vastly preferable
to the prior art assembly procedure whereby, because of the closed
front-end, the floor is moved into the interior of the bus in small
sections which are thereafter pieced together and built up
utilizing sanding and bondo operations to form the final composite
floor structure.
[0028] While the invention has been described in connection with
what is presently considered to be the most practical and preferred
embodiment, it is to be understood that the invention is not to be
limited to the disclosed embodiments but, on the contrary, is
intended to cover various modifications and equivalent arrangements
included within the spirit and scope of the description, which
scope is to be accorded the broadest interpretation so as to
encompass all such modifications and equivalent structures as is
permitted under the law.
* * * * *